Posted by: Glenn | May 8, 2012

Multitasking day

May8, 2012

Today is the first day of my summer vacation.  Yeah!!! No offense intended to any of my students that follow this blog.

I wanted to cut the hole for the air vent in the full door today.  After reading the instructions I found out that the door should be at least 72 degrees before cutting it.  The man cave was around 55.  So, I raised the thermostat and decided I could work on the half doors.  I clamped down the frame to the left door and started to sand it down so it would be somewhat straight.

Sanding half door frame

Once the air temp rose to about 75 (very warm)  I decided to go ahead and cut the 2 inch hole for the vent.  I drilled a small pilot hole for the hole cutter to follow.  You need to cut halfway on either side.  After cutting the hole I sanded down the hole to prevent cracking.  I used 150, 220, 320 and 600 grit sand paper and was pleased at the results.  I popped in the vent and it look good.

Finished Vent

One thing I didn’t go into details was the repair I made to the crack in the door.  I purchased some Weld-On for Acrylics.  I cleaned up the cracks the best I could and applied the cement.  I also drilled a small hole at the end of one of the cracks — standard practice in aviation.  Fortunately, the crack is under the door bracket and is not visible.




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